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Energy Tips – Process Heating Process Heating Tip Sheet #8 • September 2005 Industrial Technologies Program Suggested Actions • Use PHAST with current and projected energy costs to estimate energy savings from waste heat recovery. • Contact furnace or combustion system suppliers to calculate payback or return on investment. Resources U.S. Department of Energy— For additional information on process heating system efficiency, to obtain DOE’s publications and Process Heating Assessment and Survey Tool (PHAST) software, or learn more about training, visit the BestPractices Web site at www.eere.energy.gov/industry/ bestpractices. Install Waste Heat Recovery Systems for Fuel-Fired Furnaces For most fuel-fired heating equipment, a large amount of the heat supplied is wasted as exhaust or flue gases. In furnaces, air and fuel are mixed and burned to generate heat, some of which is transferred to the heating device and its load. When the heat transfer reaches its practical limit, the spent combustion gases are removed from the furnace via a flue or stack. At this point, these gases still hold considerable thermal energy. In many systems, this is the greatest single heat loss. The energy efficiency can often be increased by using waste heat gas recovery systems to capture and use some of the energy in the flue gas. For natural gas-based systems, the amount of heat contained in the flue gases as a percentage of the heat input in a heating system can be estimated by using Figure 1. Exhaust gas loss or waste heat depends on flue gas temperature and its mass flow, or in practical terms, excess air resulting from combustion air supply and air leakage into the furnace. The excess air can be estimated by measuring oxygen percentage in the flue gases. Waste Heat Recovery Heat losses must be minimized before waste heat recovery is investigated. Figure 2 highlights opportunities for energy savings. The most commonly used waste heat recovery methods are preheating combustion air, steam generation and water heating, and load preheating. Preheating Combustion Air. A recuperator is the most widely used heat recovery device. It is a gas-to-gas heat exchanger placed on the stack of the furnace that preheats incoming air with exhaust gas. Designs rely on tubes or plates to transfer heat from the exhaust gas to the combustion air and keep the streams from mixing. Figure 1. Heat in flue gas Figure 2. Heat lossesPDF Image | Waste Heat Recovery for Fuel Fired Furnaces
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